Multi-component fibers having enhanced reversible thermal properties and methods of manufacturing thereof

Abstract

The invention relates to a multi-component fiber having enhanced reversible thermal properties and methods of manufacturing thereof. The multi-component fiber comprises a fiber body formed from a plurality of elongated members, at least one of the elongated members comprising a temperature regulating material dispersed therein. The temperature regulating material comprises a phase change material. The multi-component fiber may be formed via a melt spinning process or a solution spinning process and may be used or incorporated in various products where a thermal regulating property is desired. For example, the multi-component fiber may be used in textiles, apparel, footwear, medical products, containers and packagings, buildings, appliances, and other products.

What is claimed is: 
     
       1. A fabric comprising a plurality of fibers blended together, wherein at least one fiber exhibits enhanced reversible thermal properties and comprises:
 at least one inner member comprising a blend of a first polymeric material and a non-encapsulated phase change material, wherein the inner member extends through substantially the length of the fiber, and wherein the first polymeric material has a partial affinity for the non-encapsulated phase change material, such that the non-encapsulated phase change material forms a plurality of domains dispersed within the first polymeric material; and 
 an outer member forming the exterior of the fiber and surrounding the inner member, wherein the outer member comprises a second polymeric material. 
 
     
     
       2. The fabric of  claim 1 , wherein the fabric comprises a plurality of fibers exhibiting enhanced reversible thermal properties, and wherein at least two fibers comprise different non-encapsulated phase change materials. 
     
     
       3. The fabric of  claim 1 , wherein the fiber comprises a plurality of inner members surrounded by the outer member. 
     
     
       4. The fabric of  claim 3 , wherein at least two of the inner members comprise different non-encapsulated phase change materials. 
     
     
       5. The fabric of  claim 1 , wherein the plurality of fibers are blended together by a woven process or a non-woven process. 
     
     
       6. The fabric of  claim 1 , wherein the plurality of fibers are blended together by a spunbond process. 
     
     
       7. A fabric comprising a plurality of fibers blended together, wherein at least one fiber exhibits enhanced reversible thermal properties and comprises:
 a fiber body formed from a plurality of elongated members, at least one of the elongated members comprising a temperature regulating material dispersed therein, wherein the temperature regulating material comprises a phase change material and a plurality of microcapsules that contain the phase change material, and the phase change material is selected from the group consisting of hydrocarbons. 
 
     
     
       8. The fabric of  claim 7 , wherein the at least one of the elongated members is an inner member extending through at least a portion of the fiber body. 
     
     
       9. The fabric of  claim 7 , wherein the elongated members are arranged in an island-in-sea configuration, a segmented-pie configuration, a core-sheath configuration, a side-by-side configuration, or a striped configuration. 
     
     
       10. The fabric of  claim 7 , wherein a cross sectional shape of the fiber body is circular, multi-lobal, octagonal, oval, pentagonal, rectangular, square-shaped, trapezoidal, or triangular. 
     
     
       11. The fabric of  claim 7 , wherein the fiber body is between 0.1 and 1000 denier. 
     
     
       12. The fabric of  claim 7 , further comprising an additive dispersed within at least one of the elongated members, wherein the additive is selected from the group consisting of water, surfactants, dispersants, anti-foam agents, antioxidants, thermal stabilizers, light stabilizers, UV stabilizers, microwave absorbing additives, reinforcing fibers, conductive fibers, conductive particles, lubricants, process aids, fire retardants, anti-blocking additives, anti-fogging additives, anti-static additives, anti-microbials, crosslinkers, controlled degradation agents, colorants, pigments, dyes, fluorescent whitening agents, optical brighteners, fillers, coupling agents, reinforcement agents, crystallization agents, nucleation agents, and mixtures thereof. 
     
     
       13. The fabric of  claim 7 , wherein the plurality of fibers are blended together by a woven process, a non-woven process, or a knitted process. 
     
     
       14. The fabric of  claim 1 , wherein the non-encapsulated phase change material has a transition temperature in the range of 22° C. to 40° C. 
     
     
       15. The fabric of  claim 1 , wherein the non-encapsulated phase change material is selected from the group consisting of hydrocarbons. 
     
     
       16. The fabric of  claim 15 , wherein the first polymeric material comprises polyethylene-co-vinyl acetate having between 5 percent and 90 percent by weight of vinyl acetate. 
     
     
       17. The fabric of  claim 16 , wherein the polyethylene-co-vinyl acetate has between 5 percent and 50 percent by weight of vinyl acetate. 
     
     
       18. The fabric of  claim 16 , wherein the polyethylene-co-vinyl acetate has between 18 percent and 25 percent by weight of vinyl acetate. 
     
     
       19. The fabric of  claim 1 , wherein the second polymeric material comprises a polyester. 
     
     
       20. The fabric of  claim 19 , wherein the polyester has a number average molecular weight of at least 20,000.